HEAT EXCHANGER

Heat exchanger both cool and heat fluids bypass hot and cold fluids across opposite sides of a piece of metal. The heat from one fluid is transferred through metal (which conducts heat well) into another fluid without them in fluid contact. High fluid velocity, high turbulence, high surface area contact, and larger temperature differences all contribute to more efficient heat transfer. However, different designs can work differently depending on the actual application.

Generally speaking, there are three types of common heat exchangers: plate and frame heat exchangers, shell and tube heat exchangers, and double-tube heat exchangers. They can all be effective in a variety of heat transfer applications, but optimizing efficiency, cost, and space depends heavily on the specific process in which the heat exchanger is installed. In this blog, we describe the most commonly used plate and frame, shell and tube, and double tube heat exchangers.

Plate and Frame Heat Exchanger

Plate and frame heat exchangers are also called plate heat exchangers. A plate and frame heat exchanger is a heat exchanger that uses metal plates to transfer heat between two fluids. Heat exchangers using air or gas and lower velocity fluid flow would use this arrangement. The design feature of the plate and frame heat exchanger is that the corrugated parallel plates control the alternating flow of hot and cold fluids on the surface of the plates through gaskets.
The frame plate and pressure plate compress the spacer plates together by tightening bolts. The spacer plate and the pressure plate are suspended between the upper rod and the lower guide rod. Simple mechanical design allows easy cleaning and changing capacity by adding or removing.
The cold or hot medium and the treated fluid flow in alternating channels and heat is transferred from the hotter channel to the cooler channel. Compared with shell and tube heat exchangers, plate and frame heat exchangers generally have a smaller volume and cost. Another difference between the two is that plate heat exchangers are used for medium and low-pressure fluids compared to shell and tube types for medium and high-pressure fluids.
Because of the relatively narrow paths between the plates in a plate and frame heat exchanger and the turbulent flow created by the corrugated design of the plates, its design is ideal for heating low to medium viscosity fluids. When the fluid is of moderate viscosity (consistency) or contains a small number of particles, a wider gap between the plates helps maintain flow requirements and allows particles to pass between the plates without impeding flow.
Standard boards usually have a herringbone pattern to maximize board strength under high pressure. Plates may have different chevron angles, optimized for heat transfer efficiency for a specific pressure drop. A wider flow plate has fewer contact points, helping to prevent clogging at a time. They are very effective for puree applications heated by liquid or steam.

Advantages of plate and frame heat exchangers:

Low initial purchase cost.
There are many configurations to choose from.
Higher heat transfer efficiency.
Fouling is reduced due to the high turbulence of the heat exchanger.
Significant temperature crossover can be achieved.
Small footprint.

Disadvantages of plate and frame heat exchangers:

Narrower allowable pressure and temperature ranges.
Narrow flow paths are prone to clogging/fouling.
Gasket units require special opening and closing procedures.
Due to the thin wall of the tube, the choice of material is critical.

Typical applications for plate and frame heat exchangers include:

Low to medium viscosity products with virtually no particles: milk, cream, ice cream mixes, beverages, beer, beer wort, etc.

Shell and Tube Heat Exchanger

This type of heat exchanger family, along with various structural modifications, is probably the most widely used and commonly used heat exchanger in the industry. Shell and tube heat exchangers consist of a single tube or a series of parallel tubes (ie tube bundles) enclosed within a sealed cylindrical pressure vessel (ie shell). These devices are designed so that one fluid flows through the smaller tubes, while the other fluid flows around the outside of its/them and between it/them inside the sealed enclosure.
Shell and tube heat exchangers are further classified according to the number of shell and tube heat exchangers involved, typically shell and tube heat exchangers with pressures greater than 30 bar and temperatures greater than 260°C are used for high-pressure applications. This is because the shell and tube heat exchanger is shaped to withstand high pressures.
This type of heat exchanger has some small-bore tubes installed between two tube sheets through which the main fluid moves. The tube bundle is disposed of within an enclosure through which the secondary fluid travels over the surface of the tubes. In nuclear engineering, heat generated in the core of a nuclear reactor is transferred to water vapor. To increase the heat transferred and the power generated, the heat exchange surface must be maximized, which is obtained through the use of tubes. Each steam generator can contain 3000 to 16000 cans, each tube is about 19mm in diameter.

Advantages of shell and tube heat exchangers:

Widely known and understood.
The most common type of heat exchanger service.
Widest allowable pressure and temperature range.
Sturdy mechanical structure.

Disadvantages of shell and tube heat exchangers:

The heat exchange efficiency is lower than other types of heat exchangers.
Subject to flow-induced vibration.
Not very suitable for temperature crossing conditions.
Contains stagnant zones on the shell side that can lead to corrosion.
The flow distribution is uneven.

Typical applications for shell and tube heat exchangers include:

Low to medium viscosity products: Depending on the specific product selected, may contain particles of different sizes, including pulp, purees, WFI, lotions, gels, beverages with highly contaminated dairy products.

Double tube heat exchanger

Double tube heat exchangers are a form of shell and tube heat exchangers, the simplest heat exchanger design and configuration, consisting of two or more concentric cylindrical pipes and tubes (one larger tube and one or smaller tube). According to the shell and tube heat exchanger design, one fluid flows through the smaller tubes and the other fluid flows around the smaller tubes within the larger tubes. This type of heat exchanger is known for being the most basic and affordable. Its size makes it ideal for tight spaces, offering some extra flexibility in the layout of the manufacturing process.
One of the cheapest heat exchangers in terms of design and maintenance is the double tube heat exchanger, making it ideal for small industries. While such heat exchangers are simple and inexpensive to design and maintain, their low efficiency and large-scale footprint have led the modern industry to use more efficient heat exchangers such as shell and tube heat exchangers.

Advantages of double tube heat exchangers:

You can get good heat transfer efficiency at a low capital cost.
Compared to shell and tube heat exchangers, they are small, do not require much maintenance space, and the heat transfer is acceptable.
Due to their popularity, all components are standardized, making repairs and maintenance very easy.
They have a flexible design and other additions and removals can be done easily.
You can use this type of exchanger under high pressure and high temperature.
The design of the heat exchanger allows for more thermal expansion without any expansion joints.

Disadvantages of double tube heat exchangers:

They are typically used in counterflow designs and cannot be used in some applications, but that doesn’t mean they cannot be used in parallel flow.
They have limitations in heat transfer rather than complex designs and should be used for low heat loads.
This type of heat exchanger leakage is more common (paired with more units).

Typical applications for double tube heat exchangers include:

It is difficult to cover all applications of double tube heat exchangers. They are popular in high temperature and high-pressure applications, such as boilers and compressors, and for sensible heat and cooling in engineered systems, to name a few.

As you know, heat exchanger styles can vary widely based on many variables, which can make the right choice for your brewing process daunting. In a later blog, we will explain to you how a brewery should choose a heat exchanger. Of course, if you are planning to open a brewery or expand your brewery, you may also contact us for a turnkey solution or an expansion plan.

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